Methods for the manufacture of group iv-b metallo-silicate zeolites



United States Patent 3,329,482 METHODS FOR THE MANUFACTURE OF GROUP IV-B METALLO-SILICATE ZEOLITES Dean Arthur Young, Yorba Linda, Calif., assignor to Union Oil Company of California, Los Angeles, Calif., a corporation of California No Drawing. Filed Oct. 18, 1963, Ser. No. 319,916

30 Claims. (Cl. 23113) This invention relates to a new class of synthetic, Group IV-B metallo-silicate zeolites characterized by high ion exchange capacity, and conforming substantially to the following empirical formula:

wherein D is a monovalent metal, a divalent metal, ammonium or hydrogen, n is the valence of D, x is a number from 0.5-4, X is one or more of the amphoteric metals of Group IV-B (i.e., titanium, zirconium and/or hafnium), and y is a number from about 1 to 15, preferably 210.

The invention also includes novel methods for the manufacture of said zeolites. All of these methods include as their salient feature in common the reaction, in aqueous alkaline solution, of an alkali metal silicate with one or more alkali metal peroxo-Group IV-B metallates, to form a soluble alkali metal peroxo-Group IV-B metallo-silicate complex, which is then de-peroxidized to form a metastable alkali metal Group IV-B metallo-silicate complex, which in turncan be destabilized to precipitate an insoluble alkali metal Group IV-B metallo-silicate zeolite.

The new zeolites of this invention may be prepared in either crystalline or amorphous forms, depending upon the ratios of components and methods of preparation, as will be explained more fully hereinafter. The term crystalline is used herein to designate a solid state wherein crystallinity is detectable by conventional X-ray diffraction analysis. Conversely the term amorphous is used to designate a solid state wherein crystallinityis not detectable by such methods, notwithstanding the fact that microcrystalline aggregates may, and probably do, exist even in the so-called amorphous zeolites. All of the zeolites of this invention, whether crystalline or amorphous, are useful in conventional cation exchange applications, and are also useful as adsorbents for the separation of hydrocarbon mixtures, as well as other organic and inorganic fluid mixtures. The crystalline zeolites are particularly useful as selective adsorbents, in view of their more highly uniform crystal pore sizes, a characteristic which is common to other known zeolites commonly referred to in the art as molecular sieves."

The metallo, e.g., sodium, forms of the zeolites, whether crystalline or amorphous, can be ion exchanged with ammonium salts to form the corresponding ammonium zeolites, which can then be heated to decompose the ammonium ion and convert the zeolite to a hydrogen form. These hydrogen forms possess active catalytic acidity, and can hence be employed as catalysts for the isomerization of paraflin hydrocarbons, olefins, and the like, and for hydrocarbon cracking. They can also be employed as bases for added hydrogenating components, and then become useful composite catalysts for hydrocatalytic processes such as hydroisomerization, hydroforming, hydrocracking and the like. Active hydrogenating metals which can be added to the zeolites include for example the Group VI-B and Group VIII metals, particularly nickel, iron, cobalt, platinum, palladium, rhodium, molybdenum and the like. Such metals may also form a part of the zeolitic cation structure of the zeolite by ion exchanging other metallo forms with aqueous solutions of a salt of the desired hydrogenating metal.

3,329,482 Patented July 4, 1967 A novel class of crystalline titano-silicate zeolites of this invention corresponds to the empirical formula:

(D O) :TiO (SiO (2) wherein D is a monovalent metal, a'divalent metal, ammonium or hydrogen, n is the valence of D, x is a number from 0.5 to 3, and y is a number from about 1.0 to 3.5. These titan-o-silicate zeolites appear to exhibit at least three different crystal forms, A, B and C, wherein the respective X-ray powder diffraction patterns include major d spacings as follows:

Crystal A: Crystal B: Crystal C:

7.67.9 A. 4.92:0.04 A-. 2.82:0.03 A. 3.20:0.05 A. 3.10:0;04 A. 1.84:0.03 A.

A novel class of crystalline zircono-silicate zeolites of this invention, characterized by relatively high SiO2/Zr02 mole-ratios, corresponds to the following empirical forz/n lx z 2) wherein D is a monovalent metal, a divalent metal, ammonium or hydrogen, n is a valence of D, x is a number from about 1.5 to 4, and y is a number from about 4.5 to 8.5. These zircono-silicate zeolites appear toexhibit at least three different crystal forms wherein the respective X-ray power diffraction patterns include major d spacings as follows:

' mula:

Crystal D: Crystal E: Crystal F:

5.75:0.05 A. 4.00:0.04 A. 11.510.06 A. 3.10:0.04 A. 3.l0i0.04 A. 3.81:0.04 A. 2.85:0.04 A. 2.85:0.04 A. 2.79:0.04 A.

temperatures an aqueous solution of sodium hydroxide,

sodium aluminate and sodium silicate. There has been little or no analogous development of synthetic zeolites based on the amphoteric metals of Group IV-B, even though the existence of naturally occurring zircono-silicates and titano-silicates would seem to indicate the possibility of such a development; Probably the principal reason for the lack of development of synthetic Group IV-B- metallo-silicate zeolites has been the lack of any practical method of manufacture from aqueous media. It is generally believed that crystalline zeolites are most readily prepared by precipitation from alkaline solutions of a homogeneous gel structure, which probably includes microcrystalline precursors of the macro-crystalline zeolites obtained by further digesting the gel in its mother liquor. Such techniques have heretofore not been feasible for the manufacture of Group IVB metallo-silicates because it has been impossible to' obtain a homogeneous solution of alkaline Group IV-B metallates and silicates, the alkali metal zirconates, titanates and hafnates being substantially insoluble in waterj The coprecipitation of soluble acidic Group IV-B metal compounds such as.

quite soluble in water, and may be mixed with alkaline.

H silicate solutions with the formation of a soluble peroxo- Group IV-B metallo-silicate complex. Further,- the reulting solution of peroxo-Group IV-B metallo-silicate :omplex may be heated to decompose the peroxo comlOlllld with liberation of oxygen, and the formation of a .oluble, or at least colloidally dispersed, metastable Group .V-B metallo-silicate complex which can he destabilized o precipitate a homogeneous gel, or gelatinous precipiate. The gel or gelatinous precipitate may then be sepaated, washed, and dried to form a relatively amorphous :eolite, or it may be further digested, in the mother liquor, preferably at elevated temperatures, to form a more highly :rystalline zeolite. It has further been found that, by varying the proportion of water, alkali metal, silicate and Group IV-B metallate components in the solution, zeolites 3f substantially different crystal structure and silicate con- ;ent may be obtained.

In the novel method formanufacture of the new zeolites of this invention, the critical reagent is an alkali metal peroxo-Group IV-B metallate, M,XO or hydrated forms thereof, wherein M is an alkali metal and X is an amphoteric Group IV-B metal. It will, be understood that only the three metals, titanium, zirconium and hafnium are "amphoteric among the group IV-B metals, thorium being purely basic in character and hence incapable of forming the ion-deficient coordination'complexes necessary for zeolitic structures. Any one, or a mixture, of the alkali metal peroxo-titanates, peroxozirconates or peroxo-hafnates, can be employed herein to form soluble, alkaline peroxwmetallo-silicate complexes, which ultimately can yield alkali metal zirconosilicates,valkali metal titano-silicates, alkali metal hafnosilicates, alkali metal zircono-titano silicates, alkali metal zircono-hafno-silicates, etc., all of whichv are markedly zeolitic in character.

The soluble peroxo-Group IV-B metallates can be prepared by reacting the insoluble hydrous Group IV-B metal oxides with an alkali metal hydroxide and a soluble peroxide such as sodium peroxide or hydrogenperoxide, e.g.:

zirconium sodium oxide peroxozlrconate H,Tl01+2H1O;+4Na0H NaiTlOa+Hs0 (5) titanium sodium oxide peroxotitanate HHf0z+2HzOz+4N8OH NarHlOH-5Hz0 (G) hafnium sodium oxide peroxohafnate Alternatively, they may be prepared from the acidic oxyhalide salts of the Group lV-B metals by reacting the same with hydrogen peroxide, followed by neutralization with alkali metal hydroxide, e.g.:

peroxochloride zirconyl chloride HtZrOtClrHiNaoH NB4ZI'OO+4H20+2N8C1 (8) peroxosodium zirconyl peroxochloride zirconate In place of the Group IV-B metal oxyhalides, the corresponding sulfatesalts, e.g., zirconyl sulfate, can also be employed to prepare acidic peroxo metallo-sulfate solutions which can then beconverted to the soluble alkali metal peroxo metallates.

The method illustrated by Equations 4, 5 and 6 is. advantageous in that no extraneous salts are formed in the peroxo metallate solution, which salts can in some cases interfere with the subsequent formation of soluble silicate complexes. It is disadvantageous however in that considerable time is required to being about the formation of the soluble peroxo metallates from the insoluble hydrous oxides. The method illustrated by Equations 7 and 8 is advantageous in that the formation of the peroxometal oxyhalide in Equation 7 proceeds quite rapidly; it

4 is disadvantageous however in that extraneous salts are formed upon neutralization with metal hydroxide in Equation 8.

The disadvantages of each of the foregoing methods can be substantially avoided by a three-step process involving formation of an intermediate insoluble peroxometal oxide which can then be filtered from the salt-containing solution and reacted with alkali metal hydroxide to form the soluble alkali metal peroxo metallate, as illustrated by the following equations:

ZrOClr-i-HaO+2H1Oz HeZrOsCla (soluble) (9) The MOH reactant in Equation 10 may be either an alkali metal hydroxide or ammonium hydroxide. If an alkali metal hydroxide is used, it is critical to employ no more than about two moles thereof per mole of peroxo zirconic acid, in order to avoid the formation of soluble zirconates as in Equation 11. Ammonium hydroxide however can be employed in excess since it is a sufiiciently weak base to preclude the formation of soluble peroxo metallates as shown in Equation 11.

In any of the above methods of manufacture, it is preferred to use from about 2 to 5 moles of peroxide per mole of Group IV-B metal oxide, although proportions as low as 1 mole and as high as 8 moles can in many instances be used. The hydrous oxides employed as starting material in Equations 4, 5 and 6 are preferably prepared by reacting soluble salts, e.g., zirconyl halides, titanium sulfate, etc., with an alkali metal or ammonium hydroxide. The zirconyl chloride employed in Equations 7 and 9 may result either from the dissolving of zirconium tetrachloride in water, or by dissolving commercial zirconyl chloride, ZrOCl 8H O, in water.

A number of methods have been found effective for combining the peroxo-Group IV-B metallate solutions with silicate solutions in such manner as to form an initial peroxo-Group IV-B metallo-silicate complex which is soluble, and which is capable of being heated to decompose the peroxo component and form an alkali metal Group IV-B metallo-silicate complex which is also soluble, or at least metastable as a colloidal hydrosol. According to one method, the peroxo-Group IV-B metallate solution may be admixed directly with aqueous alkali metal silicate solutions, e.g., aqueous sodium silicate. According to another method, the reactions illustrated in Equations 8 and 11 may be combined with the addition of alkaline silicate, i.e., instead of reacting the peroxo-metal oxyhalide or peroxo zirconic acid with alkali metal hydroxide alone, they are reacted with a solution of alkali metal silicate containing the required amount of excess alkali metal hydroxide. According to a third method, the acidic peroxo-metal oxyhalide solutions resulting from the reactions depicted by Equation 7 or 9 may be admixed with colloidal silica hydrosols, e.g., Ludox, and the resulting soluble mixture may then be treated with suificient alkali metal hydroxide solution to form the alkali metal peroxo- Group IV-B metallate and alkali metal silicate, and provide the desired excess of metal hydroxide. In this third method, any high-surface-area form of silica may be employed in place of silica hydrosol, e.g., silica hydrogel, silica xerogel, etc.

Following the formation of the peroxo-Group IV-B metallo-silicate solution, the peroxo oxygen is removed from the complex, preferably by heating at, e.g., 50-150 C. Decomposition can also be effected at lower temperatures over longer periods of time. In some cases it will be found that decomposition of the peroxo compound results in the substantially immediate formation of a precipitate or gel. This precipitation may be substantially complete, indicating that destabilization and de-peroxidation occurred substantially simultaneously. Or, some of the Group IV-B metal may precipitate as hydrous oxide indicating a deficiency in silica content of the solution relative to Group IV-B metal. The former situation can normally be corrected by reducing the water ratios in the solution, and/or by avoiding the presence of extraneous salts in the solution. However, even in those cases where simultaneous destabilization and de-peroxidation does occur, the resulting precipitate is highly zeolitic in character, and is hence not excluded herein. The principal disadvantage in simultaneous de-peroxidation and destabilization lies in the greater difficulty of converting the resulting amorphous precipitate to homogeneous crystalline zeolites.

In the latter case, i.e., where precipitation of excess Group IVB metal oxide occurs, there may be a resultant amorphous oxide contamination of the zeolite to be subsequently precipitated by destabilization. To avoid this result, the initial oxide precipitate formed on de-peroxida tion can be removed by filtration prior to destabilization of the mother liquor, or the precipitation may be prevented by adjusting the initial silica content of the solution to provide at least about 8 moles and up to about 30 moles thereof per mole of Group IV-B metal oxide, the ratios of the remaining components being as hereinafter prescribed in Table l.

Destabilization of the metastable alkali metal Group IV-B metallo-silicate solutions or sols, with resultant formation of hydrogels, crystalline precipitates, or gelatinous precipitates, can be brought about by a Wide variety of physical and/or chemical means. In most cases, heating at temperatures of, e.g., 75300 C. is eflFective. Simply agingthe solution at 20-50" C. is also effective in some cases. Alternatively, or in addition to heating and/or aging, it has been found that nearly any substantial alteration of the ionic equilibria of the solution Will effect a destabilization, as for example by the addition of soluble salts such as ammonium chloride, alkali metal chlorides,

nitrates, phosphates; the addition of alkali metal hy-" droxides, or weak acids such as acetic acid or carbon dioxide, or simply the addition of more water. Destabilization of the solutions by these methods may be sub stantially instantaneous, or it may in some cases be more gradual, over a period of, e.g., 10 minutes to 10 hours or more.

A surprising aspect of the destabilization phenomenon is that highly zeolitic materials rich in silica and alkali metal can be precipitated from solutions of extremely high pH, normally above 13, and in any case, above 12. This clearly indicates that discrete chemical compounds, or coordination complexes, of silica, Group IV-B metal oxide and alkali metal oxide are formed; otherwise the silica would remain in solution at these high alkalinities. However, it is not intended that the invention be limited to the actual existence of such complexes in solution; the critical operative factor is simply the existence of soluble or colloidal Group IV-B metal oxide at the high alkalinities involved.

Following destabilization, maximum crystallinity can be induced in the zeolite by digesting the gelatinous precipitate or gel at elevated temperatures in the mother liquor. Digesting may be continued at, e.g 50-300 C. or higher for periods of time ranging between about 1 hour and 6 days or more.

The alkali metal hydroxides and salts employed in the above preparations may comprise any of the metals lithium, sodium, potassium, rubidium, cesium or mixtures thereof. Generally the sodium and potassium salts are preferred.

6 Suitable overall mole-ratios of reacting components in the zeolite-forming solutions of this invention are illustrated in the following table (for zeolites of maximum crystallinity): i

1 Exclusive of alkali metal present in the form of extraneous salts such as NaCl. (X=Zr, Ti or Hf; M=alkali metal.)

Where crystallinity is not a prime consideration, reactant ratios considerably owtside the above ranges may be utilized. In particular, the SiO /XO mole-ratios may range between about 4 and 40, and the H O/M O ratios between about 150 and 10. 'Any of the alkali metal zeolites disclosed herein can be converted to other metal forms by conventional methods of ion exchange, involving simply the digestion of the alkali metal zeolite with an appropriate aqueous solution of a salt of the desired displacement metal, wherein the metal appears in the cation. Exhaustive exchange ordinarily will require several stages of digestion. By these methods the zeolitic alkali metal ions can be either partially or completely replaced by other metal ions including for example beryllium, magnesium, calcium, strontium, barium, zinc, cadmium, copper, silver, manganese, iron, cobalt, nickel, ruthenium, rhodium, palladium, platinum, and the like.

The following examples are cited to illustrate representative methods for the manufacture of zeolites of this invention, and the products obtained thereby. The various crystal forms obtained are identified by X-ray power diffraction pattern 'data obtained on a Geiger counter spectrometer with pen recorder using filtered copper K- alpha radiation (gamma=1.54050 A.)'.

Example I Preparation of zirc0no-silicate zeolite via hydrous zirc0nia1.Ten gms. of zirconyl chloride (ZrOCl -8H O) is dissolved in 50 ml. water. This solution is added to 100 ml. of 5% aqueous potassium hydroxide to form a gelatinous precipitate of hydrous zirconia. The precipitated mixture is cooled to 5 C. before adding 50 gm. of precooled 30% hydrogen peroxide. The mixture is kept at 5 C. and stirred occasionally for 2 hours. Then the temperature is slowly increased to 25 C. during a 12-hour period. During the warming much of the excess peroxide decomposes. The result is a clear solution of potassium peroxo zirconate.

The potassium peroxo zirconate solution is then mixed with an equal volume of 40 B. sodium silicate. The resulting mixture remains as a clear solution. The peroxo zirconate and the silicate react to form a stable soluble complex which remains in solution after the covalently bound peroxo oxygen is released by heating for about 30 minutes at C.

Upon the addition of 70 ml. of 6 N acetic acid, a precipitate of potassium-sodium-zircono-silicate is produced, having zeolitic and adsorptive properties.

Example 11 Preparation of zircono-silicate zeolite via peroxo zirconyl chloride.-To 1 liter of a 1.0 molar solution of zirconyl chloride is added 3 moles of hydrogen peroxide in the form of a 30% aqueous solution. No aging is required 7 8.5% SiO to provide 15 moles of SiO,. A soluble perxo zirconate-silicate complex is formed which is deomposed by aging the. solution at room temperature for 2 hours, during which period destabilization also occurs 8 22.5 weight-percent Na O, after the second exchange 3.2%, after the third 0.91% and after the fourth 0.021% This behavior is typical of crystalline materials containing tightly bound zeolitic sodium ions. An amorphous silicarith resultant formation of a gel. Following the aging at zirconia composite containing the same initial sodium oom temperature the mixture is further digested at 95 C. content, and prepared by coprecipitating zirconyl chloride or 16 hours and the resulting crystalline precipitate is filsolution with sodium silicate (no peroxo intermediate), ered 01f, washed and dried. The resulting material is a and which likewise had an initial silica/zirconia ratio of odium zircono-silicate zeolite, a sample of which had 7.3/1, was subjected to the identical ion exchange treatbe property of completely adsorbing the color from an 10 ment, and after the first stage the product contained only mmoniacal 0.01 M solution of tetrammine cupr ic ni- 7.5 weight-percent Na O, after the second 0.65%, after rate, using 10 ml. of the solution for 0.5 gm. of solid. the third 0.49%, and after the fifth 0.014%. This behavior vioreoventhe solid itself remained white. The complete is typical of amorphous coprecipitates wherein very little lisappearance of color from the solution, without impartof the sodium content is zeolitically combined. ng color to the solid, indicates that the adsorption oc- :urred entirely by ion exchange. Example I V This example illustrates the preparation and identifica- Example III tion of several crystalline sodium zircono-silicate zeolites, using silica hydrosol as the source of SiO The general "P f zlrwno'sllwate "P procedure used in each preparation was as follows: onto aczd.To 200 ml. of 1.0 M zirconyl chlonde soluzirconyl chloride (ZIOC12.H20) is mixed with a small 1111 15 added with Stlmnfi at temperature: 81 amount of water to form a saturated solution containing i 30% 2 a- The resultmg mlfmne 15 cooledfo undissolved zirconyl chloride. To the resulting slurry o. and precooled 4 1:1 ammonlllm hydroxide solut1on 1s is then added precooled (40 F.) hydrogen peroxide to added until the pH 1s 9-10, whereupon all oi the 25 form a clear solution of peroxo-zirconyl chloride. The 3011mm p p i as Peroxo lll'colflc acld which 15 peroxo-zirconyl chloride solution is then mixed with movcd y i 'f and washed with cold Water; The silica hydrosol (Ludox AM), and the mixture allowed to washed precipitate is then added to a precooled mlxture age f 2 hours at room temperature, and then cooled to composed M250 of i N sodllm} hydroxlde f 226 40 F. Aqueous sodium hydroxide solution (10 N), pre- 0f 6- Sodlum sllicaie Solutlofl- UPOII aglng the 30 cooled to 40 F., is then stirred into the peroxo zirconyl minute Ovflnight 31 C, PeIOXO Zirconic a chloride-silica hydrosol combination. This final mixture dissolves giving a clear solut is aged for 2 hours at room temperature, warmed on a UPOII boiling this Solution to decompose the PBIOXO steam bath to decompose the peroxide complex, aged for zircono-silicate, a clear Supernatant Solution is Producfld 16 hours at room temperature, and then aged for 24 hours having the following mole-ratio of components: 35 at 180 F., during which period the crystalline zeolite is formed. The resulting precipitate is collected by filtration, Na2o zro2 8 5102-119 H2O washed by resuspending twice in distilled water, and then This solution can be readily destabilized to produce gelatdried at 220 F. The proportions of reactants used in the inous zeolite precipitates by adding, e.g., 10% of water various preparations were as set forth in the following and heating, adding carbon dioxide, acetic acid, or by add- 40 table:

TABLE 2.PREPARATION OF ZEOLITES Zeolite No zs-2 zs-s zs-4 zs5 zs-7 zs-g Reagents Used:

10 N NaOH ml 200 200 300 160 200 25 13 1a 26 13 1:; 332 166 166 260 125 H20,m1 10 6 6 1o 5 5 zrociismo, gm 32.2 16.1 16.1 32.2 16.1 16.1 Mole-Ratios of Reacting Component Naio 10 20 a0 6 15 20 1 1 1 1 1 1 20 20 20 16 16 16 ing l-l0% of extraneous salts such as sodium chloride, sodium sulfate, sodium phosphate and the like.

A zeolite prepared as described above, and having a SiO /ZrO mole-ratio of 7.3/1, was subjected to ion exchange with an aqueous solution of ammonium chloride in four stages. After the first stage the zeolite contained In all of the foregoing preparations, crystalline zeolites were obtained containing substantial proportions of sodium, zirconia and silica. The major identifying char- 60 acteristics of the products, as determined by standard X- ray difiiraction analysis and chemical analysis for silica and zirconia, were as follows:

TABLE 3.ANALYSIS OF ZEOLITES All of these materials are found to display useful ion exchange and adsorption characteristics.

Example V This example illustrates that distinctly different crystal forms are obtained depending upon aging temperature, and upon order of combining of the ingredients. In this example, the silica and zirconia components were separately precombined with sodium before admixture with each other, rather than after admixture as in Example IV. The overall mole-ratio of reacting components was: 12 Na- -ZrO 15 SiO but the preparation method was as follows:

To ml. of precooled 2.0 M zirconyl chloride solution was added 8 ml. of 30% hydrogen peroxide solution. Then 30 ml. of 10 N sodium hydroxide solution was added with stirring and cooling. The resulting sodium peroxo-zirconyl chloride solution was then mixed with 46 ml. of 40 B. sodium silicate solution (B and A Code 2289), and the resulting solution was heated to 200 C. for 36 hours in a sealed vessel to effect destabilization and aging. A white crystalline precipitate was formed which was filtered off, washed, dried and subjected to X-ray diffraction analysis for crystallinity. The major d spacings were as follows: 11.5 A., 3.81 A., 3.70 A., 2.79 A.

10 bilization. After foaming and bubbling had ceased the alkaline mixture was aged for 72 hours at 85 C.

The aged precipitates were collected by filtration, and then reslurried and washed twice with large volumes of distilled water to remove any soluble components. The washed precipitates were dried for 16 hours at 110 C. and then checked for crystallinity by X-ray diffraction.

TS22TS33 Procedure-The peroxo titanyl chloride-silica hydrosol mixture was allowed to age one hour at room temperature. Then precooled F.) sodium hydroxide solution was added slowly with rapid stirring. During the mixing, additional cooling was occasionally necessary to prevent the decomposition of peroxide. The alkaline mixtures were aged 16 hours at room temperature and then warmed and stirred on a steam bath to complete the decomposition of the peroxide. Next, the mixtures were placed in closed containers to prevent evaporation and aged for 48 hours at 85 C. The resulting precipitates were collected by filtration, resuspended and washed twice with distilled water to remove any dissolved salts, and finally dried at 220 F. before measuring the X-ray diffractions.

The proportions of reactants used in the various preparations were as set forth in the following table:

TABLE 4.-PREPARATION OF ZEOLITES Zeolite No u TS-6 I TS-l2 CPS-22 TS-23 I TS-26 I TS-33 Reagents Used:

These solutions also contained excess H01 resulting from the reaction, TiCl4+HzO- T10 Clz-I-2HC1.

This preparation should be compared with zeolite 25-7 of Example IV, wherein the mole-ratios of reacting components were very similar. However, the marked difference in d spacings shows that distinctly diiferent crystal forms were produced.

In all of the foregoing preparations, crystalline zeolites were obtained containing substantial proportions of sodium, titania and silica. The major identifying characteristics of the zeolites, as determined by standard analytical methods were as follows:

TABLE 5.ANALYSIS OF ZEOLITES Zeolite No Major X-ray Diffraction spacings, A

Mole-Ratios:

Slog/Tic): Nazo/Tloz Example VI This example illustrates the preparation and identification of several crystalline sodium titano-silicate zeolites, using silica hydrosol as the source of SiO The general procedure was similar to that described in Example IV, but titanyl chloride solution was substituted for the zirconyl chloride. The peroxo-titanyl chloride solutions were prepared by mixing titanium tetrachloride solutions with 30% hydrogen peroxide solutions, as indicated in Table 4. The resulting solutions were then mixed with the indicated proportions of silica hydrosol. Following this point, the procedure for zeolites TS-6 and TS-l2 was somewhat different than for zeolites TS-22 through TS33, as follows:

TS-6-TS-12 Pr0cedure.--The peroxo titanyl chloridesilica hydrosol mixture was allowed to stand several hours at room temperature. Then sodium hydroxide solution was added and the mixture was heated on a steam bath to decompose the peroxo compounds and bring about desta- All of these zeolites are found to display useful exchange and adsorption characteristics.

Example VII This example illustrates that distinctly different crystal forms are obtained, depending upon aging temperature, and upon order of combining of the ingredients. In this example, the silica and titania components were separately precombined with sodium before admixture with each other, rather than after admixture as in Example VI. The overall mole-ratio of reacting components was: 12 N-a OTiO 15 SiO but the preparation method was as follows:

To 10 ml. of precooled 2.0 M titanyl chloride solution (prepared by adding titanium tetrachloride to water), was added 10 ml. of 30% hydrogen peroxide solution. Then 30 ml. of 10 N sodium hydroxide was added with cooling to keep the temperature below 40 F. The resulting sodium peroxo titanyl chloride solution was then mixed with 46 ml. of 40 B. sodium silicate solution, and the resulting mixture was heated to boiling to decompose the peroxides. The resulting mixture was allowed to stand several weeks at room temperature, and then the clear solution was aged in a sealed vessel for 36 hours at 200 C., during which period destabilization and aging of the precipitate took place. After the aging period the heavy white precipitate was filtered off, washed and dried. X-ray diffraction analysis showed that the precipitate was crystalline, with major d spacings at 2.82 and 1.84 A.

This preparation should be compared with zeolite TS-26 of Example VI, wherein the mole-ratios of reacting components were very similar. However, the marked difference in d spacings shows that distinctly different cryst forms were produced. 7

Example VIII This example illustrates the preparation of a four-component sodium titano-zircono-silicate zeolite. The overall mole-ratio of reacting components was: 24 Na O-TiO 30 SiO the mode of procedure being as follows:

To 10 ml. of 2.0 M zirconyl chloride solution was added 10 ml. of 2.0 M titanyl chloride solution. The resulting mixture was cooled to about 40 F., and 16 ml. of 30% hydrogen peroxide solution was added. Then 60 ml. of 10 N sodium hydroxide solution was added slowly with cooling, after which the solutionwas mixed with 92 ml. of 40 B. sodium silicate solution. The resulting clear solution was heated to boiling and then allowed to stand for several weeks at room temperature. The solution was then heated to effect destabilization, and aged for 36 hours at 200 C. in a sealed vessel. The heavy white precipitate which formed was filtered off, washed and dried. X-ray diffraction analysis showed the following major d spacings: 111.6 A.; 5.60 A.; 3.77 A.; 2.78 A.; 2.62 A.; 2.12 A.; 1.65 A.

Analysis of this diffraction data indicates the presence of a single crystalline phase; the product is hence not a crystalline mixture of the titano-silioate zeolite of Example VII and the zircono-silicate zeolite of Example V. Further analysis of the diffraction data indicates that the crystal structure is cubic with a 16.8 A. unit cell.

Results analogous to those indicated in the foregoing examples are obtained when other proportions of reactants and conditions within the broad purview of the disclosure are employed. It is hence not intended to limit the invention to the details of the examples, 'but broadly as defined in the following claims.

I claim:

1. A method for the manufacture of zeolitic alkali metal Group IV-B metallo-silicates, which comprises:

(1) combining in aqueous solution, an alkali metal peroxo-GrouppIV-B metallate and an alkali metal silicate to form an aqueous solution of an alkali metal peroxo-Group IV-B meta llo-silicate complex wherein the ratios of alkali metal, silica, Group IV-B metal and water in said solution are correlated to give the results hereinafter prescribed; and

(2) subjecting said aqueous solution of alkali metal peroxo-Group IV-B metallo-silicate complex to thermal decomposition to effect de-peroxidation and destabilization thereof with resultant liberation of oxygen, and the precipitation of a solid alkali metal Group IV-B metallo-silicate zeolite.

2. A method as defined in claim 1 wherein said precipitated alkali metal Group IV-B metallo-silicate zeolite is allowed to age in its mother liquor for a sufiicient length of time to form zeolite crystals of X-ray-diffractable size.

3. A method as defined in claim 1 wherein said precipitation of solid zeolite in step (2) is effected at a pH above about 12.0.

4. A method as defined in claim 1 wherein said alkali metal peroxo-Group IVB metallate is an alkali metal peroxo zirconate.

5. A method as defined in claim 1 wherein said alkali metal peroxo-Group IVB metallate is an alkali metal peroxo titanate.

6. A method as defined in claim 1 wherein said aqueous solution in step (1) comprises a mixture of an alkali metal peroxo zirconate and an alkali metal peroxo titanate.

7. A method for the manufacture of zeolitic alkali metal Group IV-B metallo-sili-cates, which comprises:

(1) combining in aqueous solution, an alkali metal peroxo-Group lV-B metallate and an alkali metal silicate to form an aqueous solution of an alkali metal peroxo-Group IV-B metallo-silicate complex wherein the ratios of alkali metal, silica, Group IV-B metal and water in said solution are correlated to give the results hereinafter prescribed;

(2) heating said aqueous solution of alkali metal peroxo-Group IV-B metallo-si-licate complex to effect de-peroxidation thereof with resultant liberation of oxygen and the formation of a water-soluble, metastable alkali metal Group IV-B metallo-silicate complex; and

(3) destabilizing said metastable alkali metal Group IV-B metallo-silicate complex so as to effect precipitation of a solid alkali metal Group IV-B metallosilicate zeolite.

8. A method as defined in claim 7 wherein said precipitated alkali metal Group IV-B metallo-silicate zeolite is allowed to age in its mother liquor for a suflicient length of time to form zeolite crystals of X-ray-diffractable size.

9. A method as defined in claim 7 wheren said destabilization step (3) comprises heating the mixture at elevated temperatures of about 75 to 300 C.

10. A method as defined in claim 7 wherein said destabilization step (3) comprises adding additional water to the mixture.

11. A method as defined in claim 7 wherein said destabilization step (3) comprises adding a soluble electrolyte to the aqueous mixture.

12. A method as defined in claim 7 wherein said destabilization step (3) comprises adding a soluble salt to the aqueous mixture.

13. A method as defined in claim 7 wherein said formation of aqueous solution of an alkali metal peroxo- Group IV-B metallo-silicate complex in step (1), is carried out by:

(A) forming an aqueous solution of an alkali metal peroxo-Group IV-B metallate; and

(B) combining said aqueous solution of alkali metal peroxo-Group IV-B metallate with excess alkali metal hydroxide and alkali metal silicate.

14. A method as defined in claim 7 wherein said formation of aqueous solution of an alkali metal peroxo- Group IV-B metallo-silicate complex in step (1), is carried out by:

(A) reacting an aqueous solution of a Group IV-B metal oxyhalide with hydrogen peroxide to form an aqueous solution of a peroxo-Group IV-B metal oxyhalide;

(B) mixing said aqueous solution of peroxo-Group IV-B metal oxyhalide with an aqueous silica hydrosol solution; and

(C) adding an alkali metal hydroxide to the resulting solution from step (B).

15. A method as defined in claim 7 wherein said formation of aqueous solution of an alkali metal peroxo- Group IV-B metallo-silicate complex in step (1), is carried out by:

'(A) reacting an insoluble hydrous Group IV-B metal oxide with an aqueous solution of a water-soluble peroxide and an alkali metal hydroxide to form an aqueous solution of alkali metal peroxo-Group IV-B metallate; and

(B) combining said aqueous solution of alkali metal peroxo-Group IVB metallate with excess alkali metal hydroxide and alkali metal silicate.

(C) separating said hydrous peroxo-Group IV-B metal.

oxide from the mother liquor; and

(D) reacting said separated hydrous peroxo-Group IV-B metal oxide with an aqueous solution of alkali metal hydroxide and alkali metal silicate.

17. A method as defined in claim 1 wherein the zeolite preciptated in step (2) corresponds to the general formula, (M O) :XO :(SiO wherein M is alkali metal, x is a number from 0.5-4, X is one or more of the amphoteric metals of Group IV-B, and y is a number from about 1 to 15; and wherein the ratio of reactants in step (1) falls within the following ranges:

M O/SiO 0.25-2 SiO /XO 4-40 H O/M O 150-10 18. A method as defined in claim 1 wherein said formation of aqueous solution of an alkali metal peroxo- Group IV-B metallo-silicate complex in step (1), is carried out by:

(A) forming an aqueous solution of an alkali metal peroxo-Group IV-B metallate; and

(B) combining said aqueous solution of alkali metal peroxo-Group IV-B metallate with excess alkali metal hydroxide and alkali metal silicate.

19. A method as defined in claim 1 wherein said formation of aqueous solution of an alkali metal peroxo- Grou-p IV-B metallo-silicate complex in step (1), is carried out by:

(A) reacting an aqueous solution of a Group IV-B metal oxyhalide with hydrogen peroxide to form an aqueous solution of a peroxo-Group IV-B metal oxyhalide;

(B) mixing said aqueous solution of peroxo-Group IV-B metal oxyhalide with an aqueous silica hydrosol solution; and

(C) adding an alkali metal hydroxide to the resulting solution from step (B).

20. A method as defined in claim 1 wherein said formation of aqueous solution of an alkali metal peroxo- Group IV-B metallo-silicate complex in step (1), is carried out by:

(A) reacting an insoluble hydrous Group IV-B metal oxide with an aqueous solution of a water-soluble peroxide and an alkali metal hydroxide to form an aqueous solution of alkali metal peroxo-Group IV-B metallate; and

(B) combining said aqueous solution of alkali metal peroxo-Group IV-B metallate with excess alkali metal hydroxide and alkali metal silicate.

21. A method as defined in claim 1 wherein said formation of aqueous solution of an alkali metal peroxo- Group IV-B metallo-silicate complex in step (1), is carried out by:

(A) reacting an aqueous solution of a Group IV-B metal oxyhalide with hydrogen peroxide to form a solution of peroxo-Group IV-B metal oxyhalide;

(B) adding ammonia to said aqueous solution of peroxo-Group IV-B metal oxyhalide to effect precipitation of a hydrous peroxo-Group IV-B metal oxide;

(C) separating said hydrous peroxo-Group IV-B metal oxide from the mother liquor; and

(D) reacting said separated hydrous peroxo-Group IV-B metal oxide with an aqueous solution of alkali metal hydroxide and alkali metal silicate.

'22. A method as defined in claim 7 wherein the zeolite precipitated in step (3) corresponds to the general formula, (M O) :XO (SiO wherein M is alkali metal, at is a number from 0.5-4, X is one or more of the amphoteric metals of Group IV-B, and y is a number from about 1 to 15; and wherein the ratio of reactants in step (1) falls within the following ranges:

M o/sio 0.2s 2 SiO /XO 4-40 H2O/M2O -10 23. A method for the manufacture of crystalline, zeolitic alkali metal zircono-silicates, which comprises:

(1) combining in aqueous solution, an alkali metal peroxo zirconate and an alkali metal silicate to form an aqueous solution of an alkali metal peroxo-zirconosilicate complex wherein the ratios of alkali metal, silica, zirconia and water in said solution are correlated to give the results hereinafter prescribed;

(2) heating said aqueous solution of alkali metal peroxozircono-silicate complex to decompose the peroxo component thereof with resultant liberation of oxygen and the formation of a water-soluble alkali metal zircono-silicate complex;

(3) destabilizing said aqueous solution of alkali metal zircono-silicate complex so as to effect precipitation of a solid alkali metal zircono-silicate zeolite;

(4) aging said precipitate in its mother liquor for a sufficient length of time to form zeolite crystals of X-raydiffractable size; and

(5) recovering said zeolite crystals from the aqueous mother liquor.

24. A process as defined in claim 23 wherein the moleratios of reacting components in said step (1) fall within the following ranges:

M O/SiO 0.25-2 SiO /ZrO 7-30 H2O/M2O 50-10 wherein M is an alkali metal.

25. A method as defined in claim 23 wherein said aging step (4) is carried out at temperatures of 50300 C. for about 1 hour to 6 days.

26. A method as defined in claim 23 wherein said destabilization step (3) comprises heating the mixture at elevated temperatures of about 75300 C.

27. A method for the manufacture of crystalline, zeolitic alkali metal titano-silicates, which comprises:

(1) combining in aqueous solution, an alkali metal peroxo titana-te and an alkali metal silicate to form an aqueous solution of an alkali metal peroxo titanosilicate complex wherein the ratios of alkali metal, silica, titania, and water in said solution are correlated to give the results hereinafter prescribed;

(2) heating said aqueous solution of alkali metal peroxo titano-silicate complex to decompose the peroxo component thereof with resultant liberation of oxygen and the formation of a water-soluble alkali metal titano-silicate complex;

(3) destabilizing said aqueous solution of alkali metal titano-silicate complex so as to effect precipitation of a solid alkali metal titano-silicate zeolite;

(4) aging said precipitate in its mother liquor for a suflicient length of time to form zeolite crystals of X-ray-difiractable size; and

(5) recovering said zeolite crystals from the aqueous mother liquor.

28. A process as defined in claim 27 wherein the moleratios of reacting components in said step (1) fall within the following ranges:

M -O/SiO 0.2s-2 SiO /Ti-O 7-30 H2O/M2O 50-10 wherein M is an alkali metal.

15 I V n 16 29. A method as defined in claim 27 wherein said aging OTHER REFERENCES step (4) 1s earned out at temperatures of 50-300 for Clark: The Constitution of Natural Silicates, US.

about 1 hour to 6 days. v

30. A method as defined in claim 27 wherein said de- Geologlcal 112 123:'

Mellor: Comprehensive Treatise on Inorganic and iiiil iii filfiiiiufil fiiiffififb t at 5 6, p. DAns et al.: Z. Anorg. u. Allg. Chemie, 191, 1930,

References Cited pp. 1, 12, 13 and 31-35. 7 UNITED STATES PATENTS Barrer et 211.: Jr. Chemical $00., 1959, pp. 195207. 9/1929 Jaegcr 23*113 X 10 OSCAR R. VERTIZ, Primary Examiner,

FOREIGN PATENTS EDWARD J. MEROS, Examiner.

648,923 9/1962 Canada. 

1. A METHOD FOR THE MANUFACTURE OF ZEOLITIC ALKALI METAL GROUP IV-B METALLO-SILICATES, WHICH COMPRISES: (1) COMBINING IN AQUEOUS SOLUTION, AN ALKALI METAL PEROXO-GROUP IV-B METALLATE AND AN ALKALI METAL SILICATE TO FORM AN AQUEOUS SOLUTION OF AN ALKALI METAL PEROXO-GROUP IV-B METALLO-SILICATE COMPLEX WHEREIN THE RATIOS OF ALKALI METAL, SILICA, GROUP IV-B METAL AND WATER IN SAID SOLUTION ARE CORRELATED TO GIVE THE RESULTS HEREINAFTER PRESCRIBED; AND (2) SUBJECTING SAID AQUEOUS SOLUTION OF ALKALI METAL PEROXO-GROUP IV-B METALLO-SILICATE COMPLEX TO THERMAL DECOMPOSITION TO EFFECT DE-PEROXIDATION AND DESTABILIZATION THEREOF WITH RESULTANT LIBERATION OF OXYGEN, AND THE PRECIPITATION OF A SOLID ALKALI, METAL GROUP IV-B METALLO-SILICATE ZEOLITE. 